Processes for manufacture of dough-based food products with a non-soluble granulated salt substitute

ABSTRACT

The present method is directed in one embodiment to a non-soluble, substantially white granular salt substitute for dough-based products. In certain embodiments, the dough-based product comprises a filling sealed within a pocket while in other embodiments, the dough-based product is not filled. In certain embodiments, the dough-based product is heated by baking, deep-frying or microwaving. In certain embodiments, the salt substitute of the present invention may be used in place of other large-particulate salts such as kosher salt for use on dough-based products. Certain non-dough-based products such as salted caramel ice cream, confections, as well as products utilizing a reduced-salt blend are also improved using the present invention. In certain embodiments, the salt substitute comprises white tapioca.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No.13/686,088, filed Nov. 27, 2012 which, in turn, claims the benefit andpriority of U.S. provisional patent application 61/564,644, filed Nov.29, 2011, the entire contents of which are hereby incorporated herein.

FIELD OF THE INVENTION

The present disclosure generally relates to the substitution of anon-soluble granulated product for sea salt or pretzel salt or otherlarge-particulate salts such as kosher salt for use on dough-basedproducts or non-dough-based products such as salted caramel ice cream,confections, as well as products utilizing a reduced-salt blend. In thecase of dough-based products, the invention uses granulated whitetapioca on deep fried or baked dough-based products as a substitute forsea salt or pretzel salt.

BACKGROUND

Dough-based products, either baked or deep fried, are popular snacks.One exemplary product comprises pretzels, in both soft, i.e., hot andfresh, and packaged, shelf-stable forms. Pretzels are often consumedwith a dip and several known pretzel products comprise a dip as afilling within the pretzel body. These known products are deficient in anumber of ways:

1. The traditional pretzel shape, i.e., a knot, is difficult to share asit requires ripping, cutting and/or tearing by consumers.

2. Traditional reheating methods for end consumers, including restaurantoperators for known pretzels is not optimal. Microwave cooking is fast,but the product quality is compromised. Baking requires more cookingtime than microwaving. Applicant is unaware of any known pretzelproducts comprising a filling that have been developed for deep-frying,the reasons for which are discussed further below.

3. Loss of filling during the reheating process.

4. Inconsistent salt flavoring. Addition of large particulate pretzelsalt, or sea salt on various other dough-based products, results in aninconsistency of salt flavor; some bites will be salt free and blandwhile others will be too heavily salted.

5. Labor intensive product preparation. Some soft pretzel products, andother dough-based products, require manual application of pretzel, orsea, salt; this manual step is undesirable in a restaurant setting aswell as other end user. The necessity for manually applying largeparticulate salt on these products is driven by the solubility of salt.As a consequence, during the adherence of the product to raw, moistdough and freezing and/or the heating process, i.e., baking, the largeparticulate salt may dissolve, thereby resulting in a loss of theessential characteristics of a salted pretzel, or other similardough-based product. Adhering large particulate salt to cooked doughfollowed by freezing of the cooked dough product may also cause the saltto dissolve.

These essential characteristics of, e.g., pretzel salt or sea salt whenapplied to dough-based products, which are provided by the presentinvention, comprise:

1. A consistency of saltiness in each portion or bite. Thischaracteristic is often lost in known products that rely on largeparticulate salt such as pretzel, sea or kosher salt when the largerparticulate salt is not evenly dispersed across the product.

2. The particulate size and shaping of pretzel salt, i.e., visibleirregularly shaped substantially white particles.

3. The slight crunchiness of pretzel salt or sea salt when applied todough-based products post-heating. Deep frying of, e.g., a granulatedparticulate white tapioca pearl results in a softening of the granulatedwhite tapioca to obtain a crunchiness that mimics the pretzel saltcrunch, for example. In other non-pretzel applications the crunchinessof the granulated tapioca may be modified and optimized through thermalprocessing such as baking to obtain the desired crunchiness.

BRIEF SUMMARY OF THE INVENTION

The present method is directed in one embodiment to a non-soluble,substantially white granular salt substitute for dough-based products.In certain embodiments, the dough-based product comprises a fillingsealed within a pocket while in other embodiments, the dough-basedproduct is not filled. In certain embodiments, the dough-based productis heated by baking, deep-frying or microwaving. In certain embodiments,the salt substitute of the present invention may be used in place ofother large-particulate salts such as kosher salt for use on dough-basedproducts. Certain non-dough-based products such as salted caramel icecream, confections, as well as products utilizing a reduced-salt blendare also improved using the present invention. In certain embodiments,the salt substitute comprises granulated white tapioca.

The figures and the detailed description which follow more particularlyexemplify these and other embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a flow chart for one embodiment of the presentinvention.

DETAILED DESCRIPTION

While the invention is amenable to various modifications and alternativeforms, specifics thereof are shown by way of example in the drawings anddescribed in detail herein. It should be understood, however, that theintention is not to limit the invention to the particular embodimentsdescribed. On the contrary, the intention is to cover all modifications,equivalents, and alternatives falling within the spirit and scope of theinvention.

The present disclosure is generally directed to, in one embodiment, afood product such as a dough-based product comprising non-soluble,substantially white, granular salt substitute having a texture with acrunchiness mimicking that of pretzel salt or kosher salt thereon orincorporated therein. The salt substitute may be applied or added to thefood product at a point in the manufacturing process that is prior tofreezing and subsequent heating of the raw dough-based product and,therefore, the salt substitute must be non-soluble in order to withstandthe process of adhering the salt substitute to the raw dough andsubsequent freezing of the raw dough-based product as well as deepfrying and/or baking or microwaving. In each of these embodiments, thesalt substitute comprises essential characteristics comprisingconsistency of saltiness in each bite (where a sodium-based product suchas salt is blended or mixed with the salt substitute), visiblyirregularly shaped and substantially white granulated particles and acrunchiness mimicking the crunchiness of pretzel salt.

Measuring the texture of foods, specifically “crunchiness”, andcomparing the results of the crunchiness measurements between foodproducts, may be achieved by a number of methods, including measuringsound intensity over time during chewing activity, measuring frequenciesproduced during chewing activity, and observing and recording tactilesensations during chewing activity. In this way, the crunchiness of thesalt substitute, e.g., granulated white pearl tapioca, may be comparedwith the crunchiness of other substances, e.g., pretzel salt or koshersalt. In the context of the invention, thermal processing, describedfurther below, is utilized to bring the crunchy texture of thegranulated white pearl tapioca to a comparable crunchiness with that ofpretzel salt or kosher salt.

As described above, baking and/or microwaving will participate in thedissolution of the large particulate salts when latent moisture ispresent as in known products and processes.

In certain embodiments, the food product, e.g., a dough-based productwill comprise shapes comprising: a square, a half round or half circle,a triangle, a rectangle, a cylinder, a pretzel knot, as well as anyother shaping as the skilled artisan will recognize. In some of theseembodiments, the dough-based product will comprise a pocket withfilling, e.g., a pretzel product with a pocket, that is sealed insidethe dough-based product. These filled dough-based products will beshaped from a sheet of dough having a thickness, the filling is thendeposited onto the shaped product, thereby forming the pocket when thedough is folded over the filling, encapsulating or enclosing the fillingtherein. The seal is then created which consists of compressing theedges of the dough-based product together. One of the basic complaintswith known products is the loss of filling during a heating process,e.g., baking or microwaving. This is as a result of an ineffectivelysealed edge and/or the dough sheet being too thin. An alternative is toform the dough shape, then inject the dough shape with a filling whichis a known embodiment that is also susceptible to filling loss.

In certain embodiments of the present invention, the thickness of thedough sheeting will be in the range of about 2,000 μm to about 3,000 μm.In other embodiments, the dough sheeting may comprise a thickness ofabout 2,000 μm to about 3,500 μm. In other embodiments, the doughsheeting may comprise a thickness of about 2,000 μm to about 4,000 μm.In still other embodiments, the dough sheeting may comprise a thicknessof about 3,000 μm to about 4,000 μm. In additional embodiments, thedough sheeting may comprise a thickness of about 700 μm to about 1,300μm or, in other embodiments, about 500 μm to about 4,000 μm.

The seal around at least a portion of the dough-based product comprisesa sealed edge having a width, wherein the edges of the folded dough arecompressed. In some embodiments, this seal may be ¼ inches wide while inother embodiments the seal may be ⅜ inches wide, while in still otherembodiments, the width of the sealed edge may be ½ inches wide. Incertain embodiment, the sealed edge may be at least ¼ inches wide.

The combination of the dough sheeting thickness and the sealed edgewidth create a dough-based product from which the filling, encapsulatedwithin a pocket, cannot escape during the heating process.

One or more of the dough sheeting, shaping and folding may be donemanually or using one or more machines as is known in the art.

Turning to FIG. 1, one embodiment of the present invention isillustrated as process 100.

Initially, the process begins by forming a dough comprising a flour andsodium bicarbonate and/or yeast as a leavening agent 10.

Next, the formed dough is further formed into a laminated sheet with athickness in the range of preferably 700 μm to 1,300 μm in step 20.

Next, the laminated dough sheet is formed into shapes 30. In certainembodiments, the shapes may comprise a pocket with filling depositedthereon and therein. In these embodiments, the dough sheet may be foldedover, with the filling having been enclosed within the dough sheet andpocket. Then, the edges where the folded dough come together are sealed,with a sealing width of at least ¼ inches. One preferred width for thesealed edge is ½ inch, though other widths will readily presentthemselves to the skilled artisan.

The formed shapes are then covered, e.g., by spraying or brushing andthe like, with a gum solution 40. The gum solution may comprise gumarabic, xanthan gum and/or guar gum or the equivalent.

Next, a non-soluble, substantially white, and substantially flavorlesssalt substitute is granulated to form irregularly shaped particles 50. Apreferred substance for the salt substitute is white tapioca which, ifobtained in the pearl form may be fractured to obtain the desiredparticle shaping and sizing. A preferred particle size for the saltsubstitute of the present invention simulates that of, e.g., pretzelsalt or sea salt and will be in the range of approximately 200 μm to4,000 μm. A more preferred particle size range for the salt substituteof the present invention comprises approximately 200 μm to 3,000 μm,with an even more preferred particle size range may comprise 200 μm toapproximately 1600 μm. A still more preferred size of the irregularlyshaped granulated substantially white tapioca particles is within therange of approximately 800 μm to approximately 1,200 μm.

Then, the granulated, non-soluble, substantially white and substantiallyflavorless salt substitute is adhered to the exterior of the doughshapes using the gum solution as an adherent 60.

In a preferred embodiment, the texture of the granulated saltsubstitute, e.g., the granulated tapioca described herein, shall mimicthat of pretzel salt, kosher salt and the like when eaten, including acrunchy and/or crispy texture that is not chewy or hard. To achieve thiscrunchy texture, the granulated salt substitute, e.g., granulatedtapioca, must be subjected to a thermal process to achieve the desiredcrunchy texture. The particular thermal process selected and when thethermal process occurs during the overall food production process variesby application.

For example, acceptable thermal processes for achieving the crunchytexture mimicking, e.g., pretzel or kosher salt, include inter alia,frying, baking and roasting the granulated salt substitute, e.g.,granulated tapioca as described herein. Equipment for the thermalprocessing of the salt substitute comprises, as is known in the art,fryers generally and including for example, deep fryers and paddlefryers, and ovens, e.g., conventional ovens, convection ovens andimpingement ovens. The thermal processing equipment may, or may not,include integrated conveyers as will be understood by the skilledartisan.

In each case, the thermal processing temperature and processing timeresults in granulated salt substitute, e.g., granulated tapioca, with atexture that mimics the crunchiness of pretzel salt and the like whilestill maintaining the substantially white color of the salt substitute,e.g., granulated tapioca. It is noteworthy that excessive temperatureand/or length of time in the thermal processing equipment results in atexture that does not mimic the crunchiness of pretzel or kosher salt.Among other issues, a browning or a caramelization may occur, each ofwhich are highly undesirable as one of the essential characteristics ofthe present invention is that the salt substitute comprise a substantialwhiteness. On the other hand, if the temperature and/or the processingtime in the thermal processing equipment is too low or too short,respectively, then the texture produced in the salt substitute, e.g.,granulated tapioca, will be too hard and, therefore, not crunchy wheneaten.

Exemplary thermal processing for a dough-based product may comprise deepfrying for approximately two minutes just prior to consumption. In otherembodiments, the thermal processing may occur in conjunction with otherfood processing steps. In still other embodiments, the thermalprocessing may occur before any other food processing steps. Forexample, production of the desired crunchy texture while still retainingthe substantially white color of the exemplary granulated tapioca maycomprise making the granulated tapioca at a temperature within the rangeof 300 to 375 degrees Fahrenheit for a thermal processing time withinthe range of 10 to 18 minutes. A more preferred processing time maycomprises the range of 12 to 15 minutes in combination with a preferredprocessing temperature of 350 degrees.

In other embodiments, the granulated, non-soluble, substantially whiteand substantially flavorless salt substitute may be adhered, deposited,mixed, blended, embedded or otherwise incorporated into the foodproduct, wherein the food product comprises both dough-based andnon-dough-based products, during the food production process, includingmixing or blending with a sodium-based product such as salt when the aconsistent salt flavor is required.

The exemplary dough-based product may then be frozen 70 and packaged 80for future heating which may comprise deep frying the frozen dough-basedproduct while retaining the granulated, non-soluble, substantially whiteand substantially flavorless salt substitute adhered to the dough-basedproduct after deep frying 90. An alternative heating method may comprisebaking and/or microwaving.

In certain embodiments, small particulate, i.e., crystallized, salt maybe added to the dough prior to the heating process and mixedtherethrough to ensure a consistency of salt flavoring which may belacking in currently known dough-based products relying on largeparticulate salt such as sea or pretzel salt. In some cases, thiscrystallized small particulate salt may be mixed with the gum solutionthat is applied to the exterior of the shaped dough product.

As discussed above, this process comprises addition of a visiblenon-soluble salt substitute for, e.g., sea or pretzel salt or koshersalt, that is applied at some point before the freezing of the rawdough-based product, including but not limited to immediately before thefreezing process, and its subsequent heating process. Known processesrequire addition of, e.g., sea or pretzel salt after the freezing andheating processes because of the solubility of salt resulting in itsdissolution during freezing and/or heating, thereby losing many of therequired characteristics described above, not the least of which is itsvisibility.

The above embodiments and processes thereof may be applied to a widevariety of dough-based food products including but certainly not limitedto: pretzels, bagels, crackers and the like. Any dough-based productthat may benefit from a visible large particle substantially white andnon-salt flavored salt substitute such as, e.g., white pearl tapiocagranules, is within the scope of the present invention.

In addition, non-dough-based food products such as salted caramel icecream, confections, as well as products utilizing a reduced-salt blendmay benefit from use and incorporation of the salt-substitute of thepresent invention. In these embodiments, the granulated salt substitutedescribed herein may be deposited, mixed, blended, embedded or otherwiseincorporated into the food product during the food production process,the production process ensuring that the salt substitute, e.g.,granulated tapioca, comprise the essential characteristics of aconsistency of saltiness in each bite (in the cases where a sodium-basedproduct, e.g., salt, is blended or mixed with the salt substitute of thepresent invention, visibly irregularly shaped and substantially whitegranulated particles and a crunchiness mimicking the crunchiness ofpretzel salt.

In additional embodiments, the granulated salt substitute describedherein may be blended with sodium-based products, for example butwithout limitation, salt, to produce a reduced sodium blend with theessential characteristics discussed above including a consistency ofsaltiness in each bite, visibly irregularly shaped and substantiallywhite granulated particles and a crunchiness mimicking the crunchinessof pretzel salt.

While the methods have been described in reference to some exemplaryembodiments, these embodiments are not limiting and are not necessarilyexclusive of each other, and it is contemplated that particular featuresof various embodiments may be omitted or combined for use with featuresof other embodiments while remaining within the scope of the invention.

What is claimed is:
 1. A food product comprising: non-soluble granulatedwhite pearl tapioca, the granulated tapioca comprising granule particlesizes in the range of about 200 μm to 4,000 μm; a substantially whitecolor; and a texture having a crunchiness comparable to the crunchinessof pretzel salt and/or kosher salt as measured by one of the groupconsisting of: sound intensity over time during chewing activity;frequencies produced during chewing activity, and tactile sensationsobserved during chewing activity.
 2. The food product of claim 1,further comprising dough; and a gum solution covering the dough, thenon-soluble granulated white pearl tapioca adhered to the dough usingthe gum solution as an adherent.
 3. The food product of claim 2, furthercomprising the gum solution being selected from the group consisting ofgum Arabic, xanthan gum, and guar gum.
 4. The food product of claim 2,further comprising a sodium-based product mixed with the gum solution.5. The food product of claim 1, further comprising dough, wherein thenon-soluble granulated white pearl tapioca is incorporated in the dough.6. The food product of claim 1, wherein the non-soluble granulated whitepeal tapioca is incorporated in the dough by at least one of the groupconsisting of: adhering, mixing, blending, depositing, and embedding. 7.The food product of claim 1, further comprising a sodium-based productmixed together with the non-soluble granulated white pearl tapioca, theresulting mixture incorporated in the dough.
 8. The food product ofclaim 1, wherein the food product comprises one of the group consistingof: pretzels, crackers, bagels, and ice cream.
 9. A method for achievinga crunchiness for granulated white pearl tapioca for use as a saltsubstitute and that is comparable to the crunchiness of pretzel saltthermal processing as determined by measuring the sound intensity overtime during chewing activity; frequencies produced during chewingactivity, and tactile sensations observed during chewing activity, whilemaintaining a substantially white color for the granulated white pearltapioca, the method comprising: granulating the white pearl tapioca to aparticle size within the range of about 200 μm to 4,000 μm; thermallyprocessing the granulated white pearl tapioca at a temperature withinthe range of 300 to 375 degrees Fahrenheit and for a thermal processingtime within the range of 10 to 18 minutes.
 10. The method of claim 9,further comprising adding a sodium-based product to the thermallyprocessed granulated white pearl tapioca.
 11. The method of claim 9,wherein thermally processing comprises one of the group consisting of adeep fryer, a conventional oven, a convection oven, and an impingementoven.
 12. A reduced-sodium blend food product comprising: non-soluble,substantially white, granulated white pearl tapioca thermally processedto a crunchiness comparable with the crunchiness of pretzel salt orkosher salt; and a sodium-based product.
 13. The reduced-sodium blendfood product of claim 12, wherein the sodium-based product comprisessalt.
 14. The reduced-sodium blend food product of claim 12, wherein thegranulated white pearl tapioca comprises a particle size within therange of about 200 μm to 4,000 μm.